Manually operated tray forming machine and method of using same

ABSTRACT

A machine for forming a container from a blank of sheet material includes a base, a frame coupled for rotation about the base, and a plurality of box-forming stations coupled to the frame. Each box-forming station includes a mandrel coupled to the frame. The mandrel includes a bottom face having two pairs of opposing edges, a pair of opposing side faces, and a pair of opposing end faces. Each box-forming station also includes a first pair of opposing presses each configured to be moved into close proximity to a respective end face, and a second pair of opposing presses each configured to be moved into close proximity to a respective side face. Each box-forming station additionally includes at least one manually operable mechanism configured to control a position of a first press from among the first pair of opposing presses and the second pair of opposing presses.

BACKGROUND

This invention relates generally to a manually operated machine for forming a tray from a blank of sheet material, and more specifically to methods and a manually operated machine for forming a tray by wrapping the blank around a mandrel in a field location.

Containers fabricated from paperboard and/or corrugated paperboard material are often used to store and transport goods. These containers can be square, hexagonal, or octagonal, for example. Such containers are usually formed from blanks of sheet material that are folded along a plurality of preformed fold lines to form an erected corrugated container. The panels are rotated to form end walls, side walls, a bottom wall, a top wall, and, in some cases, corner walls of the container. In addition, at least some known containers include reinforced corners or side walls for providing additional strength, including stacking strength.

Moreover, at least some known containers are formed from a blank using a tray-forming machine. At least some such machines wrap the blank about a mandrel, providing strong, uniform containers with tight tolerances and an attendant decrease in wasted blank material. In some cases, however, such as where the containers are intended to be filled at a relatively remote and/or temporary field location, it remains advantageous to transport flat blanks to the field location and form such containers on-site. At least some known tray-forming machines cannot be transported to such field locations and/or cannot be operated at such field locations, due to an absence of available power or transportation infrastructure, for example.

BRIEF DESCRIPTION OF THE DISCLOSURE

In one aspect, a machine for forming a container from a blank of sheet material is provided. The machine includes a base, a frame coupled for rotation about the base, and a plurality of box-forming stations coupled to the frame. Each box-forming station includes a mandrel coupled to the frame. The mandrel includes a bottom face having two pairs of opposing edges, a pair of opposing side faces, and a pair of opposing end faces. Each side face and end face extends generally from a corresponding edge of the bottom face and is perpendicular to the bottom face. Each box-forming station also includes a first pair of opposing presses each configured to be moved into close proximity to a respective end face of the pair of opposing end faces. Each box-forming station further includes a second pair of opposing presses each configured to be moved into close proximity to a respective side face of said pair of opposing side faces. Each box-forming station additionally includes at least one manually operable mechanism configured to control a position of a first press from among the first pair of opposing presses and the second pair of opposing presses.

In another aspect, a method for forming a container from a blank of sheet material using a machine that includes a mandrel is provided. The blank includes a bottom panel, a first and second side panel each extending from a respective side edge of the bottom panel, a first and second end panel each extending from a respective end edge of the bottom panel, a first and fourth reinforcing panel assembly each extending from a respective side edge of the first end panel, and a second and third reinforcing panel assembly each extending from a respective side edge of the second end panel. The method includes positioning each of a first end wall press, a second end wall press, a first side wall press, and a second side wall press in a receiving position. Each of the first end wall press, the second end wall press, the first side wall press, and the second side wall press are movable between the receiving position and a pressure position. The method also includes aligning the bottom panel with a bottom face of the mandrel. The method further includes moving the first end wall press from the receiving position to the pressure position such that the first end panel is pressed between the first end wall press and a first end face of the mandrel to at least partially form a first end wall of the container. The method additionally includes moving the second end wall press from the receiving position to the pressure position such that the second end panel is pressed between the second end wall press and a second end face of the mandrel to at least partially form a second end wall of the container. The method also includes moving the first side wall press from the receiving position to the pressure position such that the first side panel, at least a portion of the first reinforcing panel assembly, and at least a portion of the second reinforcing panel assembly are pressed between the first side wall press and a first side face of the mandrel to at least partially form a first side wall of the container. The method further includes moving the second side wall press from the receiving position to the pressure position such that the second side panel, at least a portion of the third reinforcing panel assembly, and at least a portion of the fourth reinforcing panel assembly are pressed between the second side wall press and a second side face of the mandrel to at least partially form a second side wall of the container.

In another aspect, a method for forming a plurality of containers from blanks of sheet material by an operator using a machine is provided. The machine includes a plurality of box-forming stations coupled to a frame. The method includes wrapping a first blank about a mandrel of a first box-forming station that is proximate to the operator, and rotating the frame about a base of the machine such that a second box-forming station arrives proximate to the operator. The method also includes wrapping a second blank about a mandrel of the second box-forming station, and rotating the frame about the base of the machine such that the first box-forming station arrives proximate to the operator. The method further includes removing the wrapped first blank from the mandrel of the first box-forming station after an adhesive on the first blank substantially sets to form a first container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of an example embodiment of a blank of sheet material that may be used with an embodiment of the tray-forming machine described herein for forming a container.

FIG. 2 is perspective view of an example embodiment of a container that may be formed from the blank shown in FIG. 1 in an open configuration.

FIG. 3 is a perspective view of the example container shown in FIG. 2 in a closed configuration.

FIG. 4 is a perspective view of an example machine for forming the container shown in FIG. 2 from the blank shown in FIG. 1.

FIG. 5 is a schematic illustration of a mandrel configured for use with the machine shown in FIG. 4.

FIG. 6 is a schematic illustration of an example of a first manually operable mechanism, configured for use with the machine shown in FIG. 4, in a catch position.

FIG. 7 is a schematic illustration of an example of a second manually operable mechanism, configured for use with the machine shown in FIG. 4, in a first position.

FIG. 8 is a schematic illustration of the example second manually operable mechanism shown in FIG. 7 in a second position.

FIG. 9 is a perspective view of the machine shown in FIG. 4 with an example box-forming station in a first configuration, prepared to receive the blank shown in FIG. 1.

FIG. 10 is a perspective view of the machine shown in FIG. 4 with the box-forming station shown in FIG. 9 in a second configuration, with the blank inserted and a first end wall press of the box-forming station in a pressure position.

FIG. 11 is a perspective view of the machine shown in FIG. 4 with the box-forming station shown in FIG. 9 in a third configuration, with a second end wall press of the box-forming station in a pressure position.

FIG. 12 is a perspective view of the machine shown in FIG. 4 with the box-forming station shown in FIG. 9 in a fourth configuration, with a first and a second side wall press of the box-forming station each in a pressure position.

DETAILED DESCRIPTION OF THE DISCLOSURE

The tray-forming machine and methods for forming corrugated containers described herein overcome the limitations of known tray-forming machines. The machine and methods described herein include a manually operated apparatus configured to wrap a blank of sheet material about a mandrel and secure the wrapped blank while adhesive sets to form the container. The machine and methods described herein also provide for the use of a plurality of box-forming stations by a single operator to facilitate an increased rate of container production. In certain embodiments, the machine and methods described herein advantageously provide for at least one step in a box-forming operation to be controlled by manually operable control mechanisms, without need for electrical power or other infrastructure.

FIG. 1 illustrates a top plan view of an example embodiment of a substantially flat blank 10 of sheet material. As shown in FIG. 1, blank 10 has a first or interior surface 12 and an opposing second or exterior surface 14. In certain embodiments, portions of exterior surface 14 and/or interior surface 12 of blank 10 include printed graphics, such as advertising and/or promotional materials. Blank 10 further defines a leading edge 16 and an opposing trailing edge 18. In an embodiment, blank 10 includes, in series from leading edge 16 to trailing edge 18, a first top panel 20, a first side panel 22, a bottom panel 24, a second side panel 26, and a second top panel 28 coupled together along preformed, generally parallel, fold lines 30, 32, 34, and 36, respectively.

More specifically, first top panel 20 extends from leading edge 16 to fold line 30, first side panel 22 extends from first top panel 20 along fold line 30, bottom panel 24 extends from first side panel 22 along fold line 32, second side panel 26 extends from bottom panel 24 along fold line 34, and second top panel 28 extends from second side panel 26 to trailing edge 18. Fold lines 30, 32, 34 and/or 36, as well as other fold lines and/or hinge lines described herein, may include any suitable line of weakening and/or line of separation known to those skilled in the art and guided by the teachings herein provided.

A container 200 (shown in FIGS. 2-3) is formed from blank 10. When container 200 is formed from blank 10, fold line 32 defines a bottom edge of first side panel 22 and a first side edge of bottom panel 24, and fold line 34 defines a second side edge of bottom panel 24 and a bottom edge of second side panel 26. Further, when container 200 is formed from blank 10, fold line 30 defines a side edge of first top panel 20 and a top edge of first side panel 22, and fold line 36 defines a top edge of second side panel 26 and a side edge of second top panel 28. In the example embodiment, vent openings 38 are defined along fold lines 30, 32, 34, and 36; however, it should be understood that blank 10 includes any suitable number of vent openings 38 along any suitable fold line. Further, vent openings 38 can have any suitable size and/or shape that enables blank 10 and/or container 200 to function as described herein.

In the example embodiment, first side panel 22 and second side panel 26 are substantially congruent and have a rectangular shape. Bottom panel 24 has an octagonal shape. More specifically, first side panel 22 and second side panel 26 have a width W₁. Bottom panel 24 has a width W₂, which is longer that width W₁. Alternatively, width W₁ is substantially equal to or longer than width W₂. Further, in the example embodiment, side panels 22 and 26 have a first height H₁, and bottom panel 24 has a first depth D₁ that is larger than first height H₁. In an alternative embodiment, height H₁ is substantially equal to or larger than depth D₁. Alternatively, first side panel 22, second side panel 26, and/or bottom panel 24 have any suitable dimensions that enable blank 10 and/or container 200 to function as described herein.

In the example embodiment, bottom panel 24 may be considered to be substantially rectangular in shape with four cut-off corners or angled edges 40, 42, 44, and 46 formed by cut lines. As such, the cut-off corner edges 40, 42, 44, and 46 of otherwise rectangular bottom panel 24 define an octagonal shape of bottom panel 24. Moreover, each angled corner edge 40, 42, 44, and 46 has a length L₁, and angled edges 40 and 44 and angled edges 42 and 46 are substantially parallel. Alternatively, bottom panel 24 has any suitable shape that enables container 200 to function as described herein. For example, bottom panel 24 may be in the shape of a rectangle having corners that are truncated by a segmented edge such that bottom panel 24 has more than eight sides. In another example, bottom panel 24 may be in the shape of a rectangle having corners that are truncated by an arcuate edge such that bottom panel 24 has four substantially straight sides and four arcuate sides. In the exemplary embodiment, each angled edge 40, 42, 44, and 46 includes a crushed area 48 that facilitates forming container 200 from blank 10. More specifically, crushed area 48 enables corner walls 210, 212, 214, and/or 216 (shown in FIG. 2) to be formed. Alternatively, blank 10 does not include crushed areas 48.

In the example embodiment, first side panel 22 includes two free side edges 50 and 52, and second side panel 26 includes two free side edges 54 and 56. Side edges 50, 52, 54, and 56 are substantially parallel to each other. Alternatively, side edges 50, 52, 54, and/or 56 are other than substantially parallel. In the example embodiment, each side edge 50, 52, 54, and 56 is connected to a respective angled edge 40, 42, 44, or 46. Each side edge 50, 52, 54, and 56 may be directly connected to a respective angled edge 40, 42, 44, or 46 or, as shown in FIG. 1, may be slightly offset from a respective angled edge 40, 42, 44, or 46 to facilitate forming container 200 from blank 10 by allowing clearance for a thickness of a panel that is directly or indirectly attached to first side panel 22 or second side panel 26.

First top panel 20 and second top panel 28 are substantially congruent and have a generally trapezoidal shape. More specifically, first top panel 20 includes an angled edge 58 extending from an intersection 60 of fold line 30 and free edge 50 toward an apex 62 and an angled edge 64 extending from an intersection 66 of fold line 30 and free edge 52 toward an apex 68. A free side edge 70 extends from apex 62 to leading edge 16, and a free side edge 72 extends from apex 68 to leading edge 16. Similarly, second top panel 28 includes an angled edge 74 extending from an intersection 76 of fold line 36 and free edge 54 toward an apex 78 and an angled edge 80 extending from an intersection 82 of fold line 36 and free edge 56 toward an apex 84. A free side edge 86 extends from apex 78 to trailing edge 18, and a free side edge 88 extends from apex 84 to trailing edge 18. In addition, first and second top panels 20 and 28 have a depth D₂ that is smaller than half of depth D₁. In an alternative embodiment, depth D₂ is substantially equal to or larger than half of depth D₁. It should be understood that first side panel 22, second side panel 26, bottom panel 24, and/or top panels 20 and/or 28 may have any suitable dimensions that enable blank 10 to function as described herein.

In the example embodiment, first top panel 20 includes a first locking slot 100 and a second locking slot 102 defined therethrough. Similarly, second top panel 28 includes locking slots 100 and 102. Each slot 100 and 102 is located, shaped, and sized to receive a stacking tab 204 (shown in FIG. 2) when container 200 is closed, as described in more detail below. In the example embodiment, a slit 104 extends from each slot 100 and/or 102 to enable stacking tab 204 to be slid through slit 104 into a respective slot 100 or 102; however, in alternative embodiments, any or all of slots 100 and/or 102 do not include slit 104. In the example embodiment, each slot 100 and 102 is generally rectangularly shaped with one slightly arcuate edge 106, and slots 100 and 102 are substantially mirror images of each other.

A first end panel 108 extends from bottom panel 24 along a fold line 110 to a free edge 112, and a second end panel 114 extends from bottom panel 24 along a fold line 116 to a free edge 118. Fold line 110 defines a bottom edge of first end panel 108 and an end edge of bottom panel 24, and fold line 116 defines a bottom edge of second end panel 114 and an end edge of bottom panel 24. First and second end panels 108 and 114 each are generally rectangular or square shaped. End panels 108 and 114 each have a depth D₃ that is shorter than depth D₁ such that end panels 108 and 114 are narrower than bottom panel 24. In the example embodiment, end panels 108 and 114 each have a height H₂ that is substantially equal to height H₁. Alternatively, height H₂ is other than equal to height H₁. In the example embodiment, fold line 110 extends between ends of angled corner edges 40 and 42, and fold line 116 extends between ends of angled corner edges 46 and 44.

Each end panel 108 and 114 includes a pair of mirror image stacking extensions 120 and 122. More specifically, each stacking extension 120 and 122 forms a portion of stacking tab 204 (shown in FIGS. 2 and 3) when container 200 is formed from blank 10. Each stacking extension 120 and 122 defines a notch 124 and has angled upper corners 126 and 128. Notch 124 is sized to receive a portion of top panel 20 or 28 when container 200 is closed, as described in more detail below. Further, in the example embodiment, each fold line 110 and 116 includes a pair of stacking slots 130 each defined by a respective cut line 132. Cut lines 132 include an upper portion 134 that has a shape that corresponds to a shape of an upper edge 136 of each stacking tab 204. When containers 200 are stacked, stacking tabs 204 of a lower container 200 are received within stacking slots 130 of an upper container 200. Moreover, when containers 200 are stacked, stacking tabs 204 do not extend into a cavity 224 (shown in FIG. 2) of an upper container 200, but rather are flush within stacking slots 130.

In the example embodiment, a reinforcing panel assembly 138 extends from each side edge of each end panel 108 and 114. Each side edge is defined by a respective one of fold lines 140, 142, 144, and 146. Fold lines 140, 142, 144, and 146 are substantially parallel to each other. Alternatively, fold lines 140, 142, 144, and/or 146 are other than substantially parallel. In the example embodiment, each reinforcing panel assembly 138 includes a free bottom edge 90. Angled edge 58, free edge 50, angled edge 40, at least a portion of free edge 70, and a first respective bottom edge 90 define a cutout 92; angled edge 64, free edge 52, angled edge 46, at least a portion of free edge 72, and a second respective bottom edge 90 define a cutout 94; angled edge 74, free edge 54, angled edge 42, at least a portion of free edge 86, and a third respective bottom edge 90 define a cutout 96; and angled edge 80, free edge 56, angled edge 44, at least a portion of free edge 88, and a fourth respective bottom edge 90 define a cutout 98. In addition, first top panel 20 is separated from adjacent reinforcing panel assemblies 138 by side edges 70 and 72, and second top panel 28 is separated from adjacent reinforcing panel assemblies 138 by side edges 86 and 88.

Each reinforcing panel assembly 138 is substantially similar and includes an outer reinforcing panel assembly 148 and an inner reinforcing panel assembly 150 connected to each other along a fold line 152. Fold line 152 defines a side edge of outer reinforcing panel assembly 148 and a side edge of inner reinforcing panel assembly 150. Moreover, outer reinforcing panel assembly 148 includes a corner panel 154 and a first reinforcing side panel 156, and inner reinforcing panel assembly 150 includes an inner reinforcing corner panel 158, a second reinforcing side panel 160, and an inner end panel 162. Each reinforcing panel assembly 138 is configured to form a reinforcing corner assembly 202 (shown in FIG. 2) when container 200 is formed from blank 10.

A respective outer reinforcing panel assembly 148 extends from each of end panels 108 and 114 along each of fold lines 140, 142, 144, and 146. Further, a respective inner reinforcing panel assembly 150 extends from each outer reinforcing panel assembly 148 along each fold line 152. In the example embodiment, a notch 164 is formed along each fold line 152 between inner reinforcing panel assembly 150 and outer reinforcing panel assembly 148. In alternative embodiments, any or all notches 164 are not present. In the example embodiment, inner reinforcing corner panel 158 and second reinforcing side panel 160 have a combined width W₃, and outer reinforcing panel assembly 148 has a width W₄ which is substantially equal to width W₃. Further, in the example embodiment, inner and outer reinforcing panel assemblies 150 and 148 have a height H₃ that is substantially equal to height H₁ of first side panel 22 and second side panel 26. In an alternative embodiment, height H₃ is other than equal to height H₁. In the example embodiment, each outer reinforcing panel assembly 148 includes a fold line 166 that divides each outer reinforcing panel assembly 148 into corner panel 154 and first reinforcing side panel 156. Fold line 166 defines a side edge of corner panel 154 and a side edge of first reinforcing side panel 156, and fold line 152 defines another side edge of first reinforcing side panel 156. In the example embodiment, corner panel 154 and first reinforcing side panel 156 are substantially rectangular.

Further, each inner reinforcing panel assembly 150 includes fold lines 168 and 170 that divide each inner reinforcing panel assembly 150 into second reinforcing side panel 160, inner reinforcing corner panel 158, and inner end panel 162. More specifically, second reinforcing side panel 160 extends from first reinforcing side panel 156 along fold line 152, inner reinforcing corner panel 158 extends from second reinforcing side panel 160 along fold line 168, and inner end panel 162 extends from inner reinforcing corner panel 158 along fold line 170 to a free edge 172. Fold line 168 defines a side edge of inner reinforcing corner panel 158 and a side edge of second reinforcing side panel 160, fold line 170 defines a side edge of inner reinforcing corner panel 158 and a side edge of inner end panel 162, and fold line 152 defines another side edge of second reinforcing side panel 160. In the example embodiment, corner panel 154 and inner reinforcing corner panel 158 are substantially congruent, and first and second reinforcing side panels 156 and 160 are substantially congruent. Further, each free edge 172 is generally co-linear with one of leading edge 16 and trailing edge 18; however, free edge 172 can have any suitable position with respect to leading edge 16 and/or trailing edge 18 that enables blank 10 and/or container 200 to function as described herein.

Each corner panel 154 and each inner reinforcing corner panel 158 have a width W₅ that is substantially equal to length L₁. In addition, each first reinforcing side panel 156 and second reinforcing side panel 160 have a width W₆ that is larger than width W₅. In alternative embodiments, width W₆ is smaller than or approximately equal to width W₅. Further, in the example embodiment, each inner end panel 162 has a depth D₄ that is equal to approximately half of depth D₃ of each of first and second end panels 108 and 114. In embodiments in which end panels 108 and/or 114 include vent holes 174, inner end panels 162 include corresponding vent holes 174 that are configured to align with vent holes 174 defined through end panels 108 and/or 114 when container 200 is formed from blank 10. In an alternative embodiment, depth D₄ is other than equal to approximately half of width D₃.

In the example embodiment, inner end panel 162 includes a minor stacking extension 176 extending from a top edge 178 thereof. Minor stacking extension 176 has a shape that at least partially corresponds to the shape of stacking extension 120 or 122 such that minor stacking extension 176 aligns with a respective stacking extension 120 or 122 to form a stacking tab 204. In the example embodiment, minor stacking extension 176 is substantially similarly shaped to a respective stacking extension 120 or 122, except minor stacking extension 176 includes a straight side edge 180 rather than a shape corresponding to notch 124. In alternative embodiments, minor stacking extension 176 has any suitable shape and position that enables blank 10 and/or container 200 to function as described herein. Further, in the example embodiment, inner end panel 162 includes a notch 182 defined in bottom edge 90. Notch 182 is shaped to correspond to at least a portion of stacking slot 130 defined in end panel 108 and/or 114. As such, when container 200 is formed from blank 10, inner end panel 162 does not obstruct stacking slot 130, such that when containers 200 are stacked, a lower stacking tab 204 (shown in FIG. 3) of a lower container 200 can fit within an upper stacking slot 130 of an upper container 200.

FIG. 2 is a perspective view of an example embodiment of a container 200 formed from blank 10 (shown in FIG. 1). FIG. 3 is a perspective view of container 200 in a closed configuration. Although container 200 is shown as being formed without a product to be contained therein, container 200 may also be formed having a product therein. Further, container 200 may include any suitable number of products of any suitable shape.

To construct container 200 from blank 10, in the example embodiment, each inner reinforcing panel assembly 150 is folded about fold line 152 such that inner reinforcing panel assembly 150 and outer reinforcing panel assembly 148 are in an at least partially overlying relationship, and such that inner end panel 162 is in an at least partially overlying relationship with at least a portion of a respective first or second end panel 108 or 114. More specifically, blank 10 is folded along fold line 152 such that corner panel 154 and inner reinforcing corner panel 158 are substantially aligned in an at least partially overlying relationship, first and second reinforcing side panels 156 and 160 are substantially aligned in an at least partially overlying relationship, and inner end panel 162 and at least a portion of first or second end panel 108 or 114 are substantially aligned in an at least partially overlying relationship. In the example embodiment, inner end panel 162, a respective end panel 108 or 114, reinforcing side panels 156 and 160, and/or corner panels 154 and 158 are secured in the above-described relationships. For example, inner end panel 162 may be adhered to a respective end panel 108 or 114, reinforcing side panels 156 and 160 may be adhered together, and/or corner panels 154 and 158 may be adhered together.

Outer and inner reinforcing panel assemblies 148 and 150 are rotated about fold lines 140, 142, 144, and 146 and fold lines 170. Further, reinforcing side panels 156 and 160 are rotated about fold lines 166 and 168 toward corner panels 154 and 158 before or after outer and inner reinforcing panel assemblies 148 and 150 are rotated about fold lines 140, 142, 144, and 146 and fold lines 170. In the example embodiment, outer and inner reinforcing panel assemblies 148 and 150 and reinforcing side panels 156 and 160 are rotated such that reinforcing side panels 156 and 160 are substantially perpendicular to end panels 108 and 114. First and second end panels 108 and 114 are then rotated about fold lines 110 and 116, respectively, toward interior surface 12. A reinforcing corner assembly 202 is formed by corner panels 154 and 158, reinforcing side panels 156 and 160, and inner end panel 162. When reinforcing corner assemblies 202 are formed, each minor stacking extension 176 aligns with a respective stacking extension 120 or 122 to form a stacking tab 204. First end panel 108 with a pair of inner end panels 162 forms a first end wall 206, and second end panel 114 with a pair of inner end panels 162 forms a second end wall 208. Each end wall 206 and 208 includes a pair of stacking tabs 204 extending from an upper edge thereof. Further, each pair of corner panels 154 and 158 forms a respective corner wall 210, 212, 214, or 216.

First side panel 22 is rotated about fold line 32 toward interior surface 12, and second side panel 26 is rotated about fold line 34 toward interior surface 12. More specifically, first side panel 22 and second side panel 26 are rotated to be substantially perpendicular to bottom panel 24. Interior surface 12 of first side panel 22 is secured to exterior surface 14 of two adjacent first reinforcing side panels 156, and interior surface 12 of second side panel 26 is secured to exterior surface 14 of two adjacent first reinforcing side panels 156. In the example embodiment, first side panel 22 and second side panel 26 are adhered to respective first reinforcing side panels 156. Alternatively, first side panel 22 and/or second side panel 26 are otherwise attached to respective first reinforcing side panels 156 using, for example, fasteners, a bonding material, such as glue or an adhesive, and/or any suitable method for attached the panels. In the example embodiment, first side panel 22 and two pairs of reinforcing side panels 156 and 160 form a first side wall 218, and second side panel 26 and two pairs of reinforcing side panels 156 and 160 form a second side wall 220.

When container 200 is formed, interior surface 12 of side walls 218 and 220 is adjacent the product. Further, height H₁ of side walls 218 and 220 is sized to correspond to a height of the products within container 200 such that height H₁ is substantially equal to or greater than the height of the products. Bottom panel 24 forms a bottom wall 222 of container 200, and bottom wall 222, side walls 218 and 220, end walls 206 and 208, and corner walls 210, 212, 214, and 216 define cavity 224 of container 200. In the exemplary embodiment, bottom edges 90 of reinforcing corner assemblies 138 are substantially aligned with fold lines 32, 34, 110, and 116 and angled edges 40, 42, 44, and 46. In FIG. 2, container 200 has a configuration referred to herein as an “open configuration.”

Referring to FIG. 3, to close container 200 and form a top wall 226, first top panel 20 is rotated about fold line 30 toward cavity 224 such that first top panel 20 is substantially perpendicular to first side panel 22 and substantially parallel to bottom panel 24. Further, second top panel 28 is rotated about fold line 36 toward cavity 224 such that second top panel 28 is substantially perpendicular to second side panel 26 and substantially parallel to bottom panel 24. As top panels 20 and 28 are rotated toward cavity 224, a respective stacking tab 204 is inserted through each locking slot 100 or 102. More specifically, a projection 228 of stacking tab 204 at least partially defined by notch 124 can be slid through slit 104 and then notch 124 can contact an edge of locking slot 100 or 102 once projection 228 is through slit 104 and/or locking slot 100 or 102.

FIG. 4 illustrates a perspective view of an example machine 1000 for forming a container, such as container 200 (shown in FIGS. 2 and 3), from a blank of sheet material, such as blank 10 (also shown in FIG. 1). Machine 1000 will be discussed thereafter with reference to forming corrugated container 200 from blank 10; however, machine 1000 may be used to form a box or any other container having any suitable size, shape, and/or configuration from a blank having any suitable size, shape, and/or configuration without departing from the scope of the present invention.

As shown in FIG. 4, machine 1000 includes a base 1002. In the example embodiment, base 1002 includes a plurality of feet 1004 each coupled to a corresponding leg 1006. Legs 1006 extend outward relative to a central, substantially vertical axis 1008. A length of legs 1006 may be selected to facilitate an increased stability of base 1002. More specifically, in the example embodiment, box-forming station 1030 includes a manual control mechanism 1104 implemented as a lever, and at least one leg 1006 is extended to a distance 1010 from axis 1008 that is greater than a distance 1106 of a fulcrum 1107 of lever 1104 from axis 1008, such that machine 1000 is resistant to tipping over in response to operational forces that may applied to lever 1104, as will be described below. In addition, at least one foot 1004 is adjustable relative to its corresponding leg 1006, in a direction generally indicated at 1012, to facilitate leveling base 1002. As such, base 1002 is configured to facilitate stable and level operation of machine 1000 at field locations which may have uneven ground and/or little or no support infrastructure. In the example embodiment, base 1002 also includes a plurality of base members 1014 coupled in suitable fashion to one or more of legs 1006 to provide rigidity to base 1002. A support structure 1016 is coupled to at least one of legs 1006 and/or at least one of base members 1014.

Machine 1000 also includes a frame 1020 coupled for rotation about base 1002. More specifically, in the example embodiment, frame 1020 is configured to be rotatable with respect to base 1002 about axis 1008. For example, frame 1020 includes a turntable 1022 coupled to support structure 1016 of base 1002. In alternative embodiments, frame 1020 is configured to rotate about an axis (not shown) other than axis 1008, which may be oriented other than substantially vertically. In an embodiment, machine 1000 includes a limited number of structural components, each of which are configured for ease of coupling to other components, to facilitate transporting machine 1000 to a field location in a disassembled condition and assembling machine 1000 at the field location.

A plurality of box-forming stations 1030 is coupled to frame 1020. In the example embodiment, each box-forming station 1030 includes at least one support member 1032 extending outwardly from frame 1020. Additionally, each box-forming station 1030 includes a mandrel 1040 coupled to the at least one support member 1032. Alternatively, each mandrel 1040 is coupled to frame 1020 in another suitable fashion. Each mandrel 1040 includes a plurality of faces, including a bottom face 1058 that faces generally outwardly from axis 1008. Bottom face 1058 has a shape that substantially corresponds to a shape of bottom panel 24 (shown in FIG. 1) of blank 10.

FIG. 5 is a schematic illustration of mandrel 1040 as viewed normal to bottom face 1058 from an outward position relative to axis 1008. Each of the faces of mandrel 1040 has a shape substantially corresponding to a shape of one or more corresponding panels of blank 10 (shown in FIG. 1). More specifically, in the example embodiment, each mandrel 1040 includes a first corner face 1042, a first end face 1044, a second corner face 1046, a first side face 1048, a third corner face 1050, a second end face 1052, a fourth corner face 1054, and a second side face 1056, each extending generally from a corresponding edge of bottom face 1058 and perpendicularly to bottom face 1058. First corner face 1042 extends at an angle between first end face 1044 and second side face 1056, second corner face 1046 extends at an angle between first end face 1044 and first side face 1048, third corner face 1050 extends at an angle between second end face 1052 and first side face 1048, and fourth corner face 1054 extends at an angle between second end face 1052 and second side face 1056. Any of the mandrel faces can be coupled directly to the at least one support member 1032 and/or to another face of mandrel 1040. Moreover, any of the mandrel faces can be solid plates, frames, plates including openings defined therein, and/or any other suitable component that provides a face and/or surface configured to enable a container to be formed from a blank as described herein.

In the example embodiment, corner faces 1042, 1046, 1050, and 1054 each have a shape substantially corresponding to a shape of corner panel 154 and inner reinforcing corner panel 158. First end face 1044 and second end face 1052 each have a shape substantially corresponding to a shape of first end panel 108 and second end panel 114, respectively. First side face 1048 and second side face 1056 each have a shape substantially corresponding to a shape of first side panel 22 and second side panel 26, respectively. Thus, an external shape of mandrel 1040 is complementary to an internal shape of at least a portion of container 200.

Returning to FIG. 4, each box-forming station 1030 of machine 1000 also includes a first pair of presses, more specifically a first end wall press 1100 and a second end wall press 1102. First end wall press 1100 is movably coupled to frame 1020 generally proximate to first end face 1044 of corresponding mandrel 1040, and second end wall press 1102 is movably coupled to frame 1020 generally proximate to second end face 1052 of corresponding mandrel 1040. First end wall press 1100 includes a substantially flat face 1112, and second end wall press 1102 includes a substantially flat face 1114. In the example embodiment, first end wall press face 1112 and second end wall press face 1114 each have a shape substantially corresponding to a shape of first end panel 108 and second end panel 114, respectively. Furthermore, first end wall press 1100 and second end wall press 1102 each are movable between a receiving position 1108 and a pressure position 1110.

First end wall press 1100 is configured such that its face 1112 is positioned in close proximity to first end face 1044 when first end wall press 1100 is in pressure position 1110, and second end wall press 1102 is configured such that its face 1114 is positioned in close proximity to second end face 1052 when second end wall press 1102 is in pressure position 1110. In this context, “close proximity” is defined as proximity within a distance that is less than or equal to a maximum desired wall thickness of container 200. Conversely, first end wall press 1100 is configured such that its face 1112 is positioned away from first end face 1044 when first end wall press 1100 is in receiving position 1108, and second end wall press 1102 is configured such that its face 1114 is positioned away from second end face 1052 when second end wall press 1102 is in receiving position 1108.

Each box-forming station 1030 further includes a first manually operable mechanism 1103 configured to control a position of a first press of first pair of opposing presses 1100, 1102. In the example embodiment, first manually operable mechanism 1103 is operably coupled to first end wall press 1100 and configured to mechanically control the position of first end wall press 1100. More specifically, first end wall press 1100, frame 1020, and first manually operable mechanism 1103 are coupled together such that first end wall press 1100 is disposed in receiving position 1108 when first manually operable mechanism 1103 is set to a catch position 1121, and first end wall press 1100 is disposed in pressure position 1110 when first manually operable mechanism 1103 is set to a release position 1123. First manually operable mechanism 1103 provides for at least one step in the box-forming operation to be mechanically controlled by an operator using a manually operated control mechanism, as will be described herein. Alternatively or additionally, first manually operable mechanism 1103 may be configured to control one of a second pair of opposing presses, as will be described herein.

FIG. 6 illustrates a schematic view of the example embodiment of first manually operable mechanism 1103 in catch position 1121, and FIG. 7 illustrates a schematic view of the example embodiment of first manually operable mechanism 1103 in release position 1123. With reference to FIGS. 4, 6, and 7, first manually operable mechanism 1103 includes an interface plate 1125 rotatably coupled to frame 1020. More specifically, interface plate 1125, like first end wall press 1100, is rotatable in the plane of illustration of FIGS. 6 and 7. Defined in interface plate 1125 are a release slot 1127, a catch slot 1129 that is disposed substantially parallel to release slot 1127, and a transition slot 1131 extending between release slot 1127 and catch slot 1129. Release slot 1127, catch slot 1129, and transition slot 1131 are in flow communication to form a continuous slot, and a first cross bar 1133 is received in the continuous slot.

First cross bar 1133 is coupled to first end wall press 1100. Catch slot 1129 has a relatively short length, such that when first cross bar 1133 is positioned in catch slot 1129, catch slot 1129 permits only limited rotation of first end wall press 1100 toward mandrel 1040 before first cross bar 1133 is mechanically stopped by an end of catch slot 1129. Thus, interface plate 1125 is operable to suspend first end wall press 1100 in receiving position 1108 when first cross bar 1133 is positioned in catch slot 1129. In contrast, release slot 1127 is elongated relative to catch slot 1129, such that release slot 1127 permits rotation of first end wall press 1100 towards mandrel 1040 into pressure position 1110 when first cross bar 1133 is positioned in release slot 1127.

A handle 1105 extends from first end wall press 1100 proximate to first cross bar 1133. To operate first manually operable mechanism 1103 to place first end wall press 1100 in receiving position 1108, an operator grasps handle 1105 and raises first end wall press 1100 until cross bar 1133 traverses transition slot 1131 into catch slot 1129. The operator may then release handle 1105, and first end wall press 1100 rotates slightly downward under its own weight until cross bar 1133 is mechanically stopped in catch slot 1129, suspending first end wall press 1100 in receiving position 1108.

A holding member 1109 is coupled to interface plate 1125 proximate to transition slot 1131. When first end wall press 1100 is in receiving position 1108, holding member 1109 also is proximate to handle 1105. To operate first manually operable mechanism 1103 to place first end wall press 1100 in pressure position 1110, the operator grasps handle 1105, lifts handle 1105 slightly to move cross bar 1133 along catch slot 1129 toward transition slot 1131, and presses holding member 1109. For example, holding member 1109 is configured to enable the operator to press holding member 1109 using the thumb of the hand that is grasping handle 1105. Holding member 1109 moves interface plate 1125 relative to cross bar 1133 such that cross bar 1133 moves through transition slot 1131 into release slot 1127. The operator may then use handle 1105 to guide first end wall press 1100 as it rotates downward under its own weight into pressure position 1110, where, in the example embodiment, cross bar 1133 is mechanically stopped in release slot 1127. Additionally or alternatively, first end wall press 1100 may rotate downward until first end wall press face 1112 is mechanically stopped by mandrel 1040.

Each box-forming station 1030 further includes a second manually operable mechanism 1122 configured to control a position of a second press of first pair of opposing presses 1100, 1102. In the example embodiment, second manually operable mechanism 1122 is operably coupled to second end wall press 1102 and configured to mechanically control the position of second end wall press 1102. More specifically, second end wall press 1102, frame 1020, and second manually operable mechanism 1122 are coupled together such that second end wall press 1102 is disposed in receiving position 1108 when second manually operable mechanism 1122 is set to a first position 1120, and second end wall press 1102 is disposed in pressure position 1110 when second manually operable mechanism 1122 is set to a second position 1124. Second manually operable mechanism 1104 provides for at least one step in the box-forming operation to be mechanically controlled by an operator using a manually operated control mechanism, as will be described herein. Alternatively or additionally, second manually operable mechanism 1122 may be configured to control one of a second pair of opposing presses, as will be described herein.

FIG. 7, discussed above, illustrates a schematic view of the example embodiment of second manually operable mechanism 1122 in first position 1120, and FIG. 8 illustrates a schematic view of the example embodiment of second manually operable mechanism 1122 in second position 1124. With reference to FIGS. 4, 7, and 8, in the example embodiment, second manually operable mechanism 1122 is activated by a lever 1104, although any other suitable structure that allows second manually operable mechanism 1122 to function as described herein may be used. In addition, in the example embodiment, second manually operable mechanism 1122 is coupled to frame 1020 at least partially indirectly through first end wall press 1100, and is configured for use when first end wall press 1100 is in pressure position 1110. In alternative embodiments, second manually operable mechanism 1122 is configured for use when first end wall press 1100 is in receiving position 1108, or second manually operable mechanism 1122 is configured for use when first end wall press 1100 is in either of receiving position 1108 and pressure position 1110. In still other alternative embodiments, second manually operable mechanism 1122 is coupled directly to frame 1020.

In the example embodiment, lever 1104 is rotatably coupled to first end wall press 1100 via a second cross bar 1119. More specifically, lever 1104 is rotatable in the plane of illustration in FIGS. 7 and 8, and second cross bar 1119 rotates with lever 1104. In addition, second cross bar 1119 is substantially rigidly coupled to a linkage plate 1126, such that linkage plate 1126 also rotates with lever 1104. Linkage plate 1126 is coupled to a first end of a rod 1118 at a pinned joint 1128. An opposing second end of rod 1118 is coupled to second end wall press 1102. To operate second manually operable mechanism 1122 to place second end wall press 1102 into pressure position 1110, the operator grasps lever 1104 and rotates it from first position 1120 to second position 1124. Linkage plate 1126 rotates with lever 1104, rotating pinned joint 1128 from a relatively lower elevation 1139 (shown in FIG. 7) to a relatively higher elevation 1141 (shown in FIG. 8). This change in position of pinned joint 1128 pulls rod 1118 upwards, and rod 1118 causes second end wall press 1102 to rotate towards mandrel 1040 into pressure position 1110.

Similarly, to operate second manually operable mechanism 1122 to place second end wall press 1102 into receiving position 1108, the operator grasps lever 1104 and rotates it from second position 1124 to first position 1120. Linkage plate 1126 rotates with lever 1104, rotating pinned joint 1128 from relatively higher elevation 1141 to relatively lower elevation 1139. This change in position of pinned joint 1128 lowers rod 1118 downwards, and rod 1118 causes second end wall press 1102 to rotate away from mandrel 1040 into receiving position 1108. In alternative embodiments, any suitable linkage may be used to operably couple second end wall press 1102 to lever 1104.

With reference to FIG. 4, each box-forming station 1030 of machine 1000 also includes a second pair of presses, more specifically a first side wall press 1130 and a second side wall press 1132. First side wall press 1130 is movably coupled to frame 1020 generally proximate to first side face 1048 of corresponding mandrel 1040, and second side wall press 1132 is movably coupled to frame 1020 generally proximate to second side face 1056 of corresponding mandrel 1040. First side wall press 1130 includes a substantially flat side face 1134, and second side wall press 1132 includes a substantially flat side face 1136. In addition, in the example embodiment, first side wall press 1130 includes a pair of mitered faces 1142 and 1144 extending from opposite ends of side face 1134, and second side wall press 1132 includes a pair of mitered faces 1146 and 1148 extending from opposite ends of side face 1136. In the example embodiment, first side wall press face 1134 and second side wall press face 1136 each have a shape substantially corresponding to a shape of first side panel 22 and second side panel 26, respectively, and mitered faces 1142, 1144, 1146, and 1148 each have a shape substantially corresponding to corner panels 154 and inner reinforcing corner panels 158 of blank 10. First side wall press 1130 and second side wall press 1132 each are movable between a receiving position 1138 and a pressure position 1140.

First side wall press 1130 is configured such that, when first side wall press 1130 is in pressure position 1140, side face 1134 is positioned in close proximity to first side face 1048, mitered face 1142 is positioned in close proximity to second corner face 1046, and mitered face 1144 is positioned in close proximity to third corner face 1050. Similarly, second side wall press 1132 is configured such that, when second side wall press 1132 is in pressure position 1140, side face 1136 is positioned in close proximity to second side face 1056, mitered face 1146 is positioned in close proximity to first corner face 1042, and mitered face 1148 is positioned in close proximity to fourth corner face 1054. Conversely, first side wall press 1130 is configured such that side face 1134, mitered face 1142, and mitered face 1144 are positioned away from mandrel 1040 when first side wall press 1130 is in receiving position 1138, and second side wall press 1132 is configured such that side face 1136, mitered face 1146, and mitered face 1148 are positioned away from mandrel 1040 when second side wall press 1132 is in receiving position 1138.

In the example embodiment, first side wall press 1130 is coupled to frame 1020 via a hinge 1150, and second side wall press 1132 is coupled to frame 1020 via a hinge 1152. Hinge 1150 and hinge 1152 are configured such that first side wall press 1130 and second side wall press 1132 are movable by hand between receiving position 1138 and pressure position 1140 by a typical human operator. In alternative embodiments, any suitable mechanical structure may be used to movably couple first side wall press 1130 and second side wall press 1132 to frame 1020.

Additionally, each box-forming station includes a locking mechanism 1160 configured to releasably maintain first side wall press 1130 and second side wall press 1132 in pressure position 1140. In the example embodiment, locking mechanism 1160 includes a first locking member 1162 coupled to first side wall press 1130, a second locking member 1164 coupled to second side wall press 1132, and a clasp 1166 operable to releasably couple first locking member 1162 and second locking member 1164 when first side wall press 1130 and second side wall press 1132 are in pressure position 1140. Clasp 1166 is configured to apply tension to first locking member 1162 and second locking member 1164 in the coupled position, thereby maintaining first side wall press 1130 and second side wall press 1132 in close proximity to mandrel 1040. In alternative embodiments, any suitable mechanical structure may be used to releasably maintain first side wall press 1130 and second side wall press 1132 in pressure position 1140. For example, in an embodiment, locking mechanism 1160 includes respective springs coupled to hinge 1150 and hinge 1152 that each are configured to selectively bias first side wall press 1130 and second side wall press 1132, respectively, into pressure position 1140 when first side wall press 1130 and second side wall press 1132 are moved to within a predefined distance of pressure position 1140.

In another alternative embodiment, at least one manually operable mechanism (not shown) similar to first manually operable mechanism 1103 or second manually operable mechanism 1122, described above, is configured to control the second pair of opposing presses 1130, 1132. The manual control mechanism may be a lever, a hand-crank, or any other suitable structure that allows the manually operable mechanism to control the second pair of presses 1130, 1132 in a manner similar to that described for the control of either of the first pair of presses 1100, 1102.

FIGS. 9-12 illustrate perspective views of machine 1000 with one of the plurality of box-forming stations 1030 shown at different stages of operation in forming container 200 from blank 10. FIG. 9 is a perspective view of box-forming station 1030 in a first configuration, prepared to receive blank 10. Manual control mechanism 1104 is set to first position 1120. Accordingly, as described above, first end wall press 1100 and second end wall press 1102 are in receiving position 1108. In addition, first side wall press 1130 and second side wall press 1132 are in receiving position 1138.

With reference to FIGS. 1, 4-5, and 9, prior to presenting blank 10 to machine 1000, a human operator may rotate each inner reinforcing panel assembly 150 about respective fold line 152 towards interior surface 12 of outer reinforcing panel assembly 148, as illustrated in FIG. 9, to prepare reinforcing panel assemblies 138 for subsequent steps. For each reinforcing panel assembly 138, the operator also may apply a suitable adhesive to interior surface 12 of at least one of inner end panel 162 and respective end panel 108 or 114, at least one of reinforcing side panels 156 and 160, and at least one of corner panels 154 and 158. Alternatively, a suitable adhesive may have been pre-applied to the described areas of blank 10. The operator then orients blank 10 such that bottom panel 24 aligns with mandrel bottom face 1058.

FIG. 10 is a perspective view of box-forming station 1030 in a second configuration, with blank 10 inserted and first end wall press 1100 in pressure position 1110. With reference to FIGS. 1, 4-5, and 9-10, to reach the configuration shown in FIG. 10, the operator places bottom panel 24 against mandrel bottom face 1058 in juxtaposed face-to-face relationship. For each of the two reinforcing panel assemblies 138 that extend from first end panel 108, the operator also rotates each reinforcing panel assembly 138 towards interior surface 12 of end panel 108. For example, the operator rotates each inner reinforcing panel assembly 150 about respective fold line 152 towards interior surface 12 such that corner panel 154 and inner reinforcing corner panel 158 are substantially aligned in an at least partially overlying relationship, first and second reinforcing side panels 156 and 160 are substantially aligned in an at least partially overlying relationship, and inner end panel 162 and at least a portion of first end panel 108 are substantially aligned in an at least partially overlying relationship.

Additionally, the operator at least partially rotates first end panel 108, along with each aligned inner end panel 162, about fold line 110 towards mandrel first end face 1044, such that exterior surface 14 of first end panel 108 is in position to be contacted by face 1112 when first end wall press 1100 is moved from receiving position 1108 to pressure position 1110. While first end panel 108 is so positioned, the operator moves first manually operable mechanism 1103 into release position 1123, such that first end wall press 1100 moves into pressure position 1110, as described above. First end panel 108, along with each aligned inner end panel 162, is pressed between first end wall press face 1112 and mandrel first end face 1044. Thus, the pressure exerted by first end wall press 1100 facilitates adhering first end panel 108 to each aligned inner end panel 162 to form first end wall 206 of container 200.

FIG. 11 is a perspective view of box-forming station 1030 in a third configuration, with blank 10 inserted and first end wall press 1100 and second end wall press 1102 in pressure position 1110. With reference to FIGS. 1, 4-5, and 9-11, to reach the configuration shown in FIG. 11, for each of the two reinforcing panel assemblies 138 that extend from second end panel 114, the operator rotates each reinforcing panel assembly 138 towards interior surface 12 of end panel 114. For example, the operator rotates each inner reinforcing panel assembly 150 about respective fold line 152 towards interior surface 12 such that corner panel 154 and inner reinforcing corner panel 158 are substantially aligned in an at least partially overlying relationship, first and second reinforcing side panels 156 and 160 are substantially aligned in an at least partially overlying relationship, and inner end panel 162 and at least a portion of second end panel 114 are substantially aligned in an at least partially overlying relationship.

Additionally, the operator at least partially rotates second end panel 114, along with each aligned inner end panel 162, about fold line 116 towards mandrel second end face 1052, such that exterior surface 14 of second end panel 114 is in position to be contacted by face 1114 when second end wall press 1102 is moved from receiving position 1108 to pressure position 1110. While second end panel 114 is so positioned, the operator operates second manually operable mechanism 1122 into second position 1124, such that second end wall press 1102 moves into pressure position 1110, as described above. Second end panel 114, along with each aligned inner end panel 162, is pressed between second end wall press face 1114 and mandrel second end face 1052. Thus, the pressure exerted by second end wall press 1102 facilitates adhering second end panel 114 to each aligned inner end panel 162 to form second end wall 208 of container 200.

FIG. 12 is a perspective view of box-forming station 1030 in a fourth configuration, with blank 10 inserted, first end wall press 1100 and second end wall press 1102 each in pressure position 1110, and first side wall press 1130 and second side wall press 1132 each in pressure position 1140. With reference to FIGS. 1, 4-5, and 9-12, to reach the configuration shown in FIG. 9, the operator ensures that, for a first reinforcing panel assembly 138 coupled to first end panel 108, a corresponding first overlying set of corner panel 154 and inner reinforcing corner panel 158 is positioned generally adjacent to mandrel second corner face 1046, and a corresponding first overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 is positioned generally adjacent to mandrel first side face 1048. The operator further ensures that, for a second reinforcing panel assembly 138 coupled to second end panel 114, a corresponding second overlying set of corner panel 154 and inner reinforcing corner panel 158 is positioned generally adjacent to mandrel third corner face 1050, and a corresponding second overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 is positioned generally adjacent to mandrel first side face 1048. For example, if the first and second reinforcing panel assemblies 138 are not in the described position after respective end panels 108 and 114 are pressed by respective end wall presses 1100 and 1102, the operator may manually rotate the respective overlying set of corner panel 154 and inner reinforcing corner panel 158 toward respective mandrel corner face 1046 and 1050 about respective fold line 170 and fold line 140 or 144. Additionally or alternatively, the operator may manually rotate the respective overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 toward mandrel first side face 1048 about respective fold lines 166 and 168.

In addition, the operator may apply a suitable adhesive to at least one of exterior surface 14 of each reinforcing panel assembly 138 and interior surface 12 of a corresponding portion of the adjacent side panel 22. For example, the operator applies a suitable adhesive to at least one of exterior surface 14 of first reinforcing side panel 156 and interior surface 12 of an adjacent portion of side panel 22. Alternatively, a suitable adhesive may have been pre-applied to the described areas of blank 10. The operator also at least partially rotates first side panel 22 about fold line 32 towards mandrel first side face 1048, such that exterior surface 14 of first side panel 22 is in position to be contacted by side face 1134 when first side wall press 1130 is moved from receiving position 1138 to pressure position 1140. While first side panel 22 is so positioned, the operator moves first side wall press 1130 into pressure position 1140, as described above. First side panel 22, along with the first and second overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, is pressed between side face 1134 of first side wall press 1130 and mandrel first side face 1048; the first overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1142 and mandrel second corner face 1046; and the second overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1144 and mandrel third corner face 1050.

Thus, for each of the first and second overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, the pressure exerted by first side wall press 1130 facilitates adhering first reinforcing side panel 156, second reinforcing side panel 160, and first side panel 22 together to form first side wall 218 of container 200. Moreover, for the first overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by first side wall press 1130 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form first corner wall 210, and for the second overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by first side wall press 1130 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form second corner wall 212 of container 200.

Similarly, the operator ensures that, for a third reinforcing panel assembly 138 coupled to second end panel 114, a corresponding third overlying set of corner panel 154 and inner reinforcing corner panel 158 is positioned generally adjacent to mandrel fourth corner face 1054, and a corresponding third overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 is positioned generally adjacent to mandrel second side face 1056. The operator further ensures that, for a fourth reinforcing panel assembly 138 coupled to first end panel 108, a corresponding fourth overlying set of corner panel 154 and inner reinforcing corner panel 158 is positioned generally adjacent to mandrel first corner face 1042, and a corresponding fourth overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 is positioned generally adjacent to mandrel second side face 1056. For example, if the third and fourth reinforcing panel assemblies 138 are not in the described position after respective end panels 108 and 114 are pressed by respective end wall presses 1100 and 1102, the operator may manually rotate the respective overlying set of corner panel 154 and inner reinforcing corner panel 158 toward respective mandrel corner face 1054 and 1042 about respective fold line 170 and fold line 146 or 142. Additionally or alternatively, the operator may manually rotate the respective overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 toward mandrel second side face 1056 about respective fold lines 166 and 168.

In addition, the operator may apply a suitable adhesive to at least one of exterior surface 14 of each reinforcing panel assembly 138 and interior surface 12 of a corresponding portion of the adjacent side panel 26. For example, the operator applies a suitable adhesive to at least one of exterior surface 14 of first reinforcing side panel 156 and interior surface 12 of an adjacent portion of side panel 26. Alternatively, a suitable adhesive may have been pre-applied to the described areas of blank 10. The operator also at least partially rotates second side panel 26 about fold line 34 towards mandrel second side face 1056, such that exterior surface 14 of second side panel 26 is in position to be contacted by side face 1136 when second side wall press 1132 is moved from receiving position 1138 to pressure position 1140. While second side panel 26 is so positioned, the operator moves second side wall press 1132 into pressure position 1140, as described above. Second side panel 26, along with the third and fourth overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, is pressed between side face 1136 of second side wall press 1132 and mandrel second side face 1056; the third overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1148 and mandrel fourth corner face 1054; and the fourth overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1146 and mandrel first corner face 1042.

Thus, for each of the third and fourth overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, the pressure exerted by second side wall press 1132 facilitates adhering first reinforcing side panel 156, second reinforcing side panel 160, and second side panel 26 together to form second side wall 220 of container 200. Moreover, for the third overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by second side wall press 1132 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form third corner wall 214, and for the fourth overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by second side wall press 1132 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form fourth corner wall 216 of container 200.

In the example embodiment, after first side wall press 1130 and second side wall press 1132 are each positioned in pressure position 1140, the operator releasably couples first locking member 1162 and second locking member 1164 together using clasp 1166, as described above. In alternative embodiments, any other suitable structure is provided to maintain first side wall press 1130 and second side wall press 1132 in pressure position 1140, as described above.

With reference to FIGS. 1-12, in the example embodiment, a single operator may advantageously use the plurality of box-forming stations 1030 on machine 1000 to increase a rate of forming containers 200. More specifically, the operator wraps a first blank 10 about mandrel 1040 of a first box-forming station 1030 that is proximate to the operator. For example, the operator may wrap the first blank by setting the first pair of presses, that is, first end wall press 1100 and second end wall press 1102, to pressure position 1110 and setting the second pair of presses, that is, first side wall press 1130 and second side wall press 1132, to pressure position 1140, as described above. In the example embodiment, the operator maintains first manually operable mechanism 1103 in release position 1123 and second manually operable mechanism 1122 in second position 1124, and locks locking mechanism 1160 to maintain the first blank in the wrapped configuration. The operator then rotates frame 1020 about axis 1008 such that a second box-forming station 1030 arrives proximate to the operator. For example, the operator may rotate frame 1020 by pushing, for example, first side wall press 1130 of the first box-forming station to the side, allowing frame 1020 to rotate until the second box-forming station 1030 arrives proximate to the operator (for example, a rotation of about ninety degrees in the example embodiment in which machine 1000 has four box-forming stations), and halting the rotation by placing the operator's hand on second side wall press 1132, for example, of the second box-forming station 1030. The operator then obtains a second blank 10, for example, from a stack (not shown) of blanks 10 located beside the operator, and wraps the second blank 10 about mandrel 1040 of the second box-forming station 1030 in the same fashion described above. The operator may rotate frame 1020 a second time and repeat the procedure with a third blank 10 at a third box-forming station 1030, and rotate frame 1020 a third time and repeat the procedure with a fourth blank 10 at a fourth box-forming station 1030.

Moreover, the operator may rotate frame 1020 a fourth time to bring the first box-forming station 1030 proximate to the operator again. In the example embodiment, the adhesive applied to first blank 10 prior to or during the wrapping process is substantially set when the operator rotates frame 1020 to reach first box-forming station 1030 again. For example, the time required to wrap the second, third, and fourth blanks 10 at respective second, third, and fourth box-forming stations 1030, and/or the pressure applied to the walls of container 200 by the first pair of presses 1100, 1102 and second pair of presses 1130, 1132 of the first box-forming station, facilitates setting of the adhesive on first blank 10. Thus, the operator may uncouple locking mechanism 1160, move the second pair of presses 1130, 1132 to receiving position 1138, move second manually operable mechanism 1122 to first position 1120 to return second end wall press 1102 to receiving position 1108, move first manually operable mechanism 1103 to catch position 1121 to return first end wall press 1100 to receiving position 1108, and remove a first container 200 (formed from first blank 10) from mandrel 1040 of the first box-forming station 1030. The first container 200 will be in the configuration shown in FIG. 2, with the top open, ready to be filled with product. The operator may then obtain a fifth blank 10 and wrap it about mandrel 1040 of the first box-forming station 1030, continuing to form a plurality of containers 200 from a respective plurality of blanks 10 in the same fashion described above.

While machine 1000 includes four box-forming stations 1030 in the example embodiment, it should be understood that any number of box-forming stations 1030 may be included on machine 1000 without departing from the scope of the current disclosure. Moreover, although machine 1000 may be advantageously operated by a single operator, it is also contemplated that multiple operators may use machine 1000 simultaneously. For example, in an embodiment, two operators are positioned respectively on opposite sides of machine 1000, such that a first operator may work at the first box-forming station while a second operator works at the third box-forming station. The use of two operators may be advantageous in embodiments where a time required to wrap a complex blank about a mandrel is such that the adhesive on a previously wrapped blank substantially sets after one additional blank is wrapped.

The example embodiments described herein provide a manually operated machine and methods for forming a tray from a blank of sheet material by wrapping the blank around a mandrel. As compared to typical hand-forming of containers from blanks, the example embodiments advantageously provide an increased precision in the folding and positioning of panels of the blank through the use of the mandrel. As a result, the blanks used may be manufactured to tighter tolerances, thereby facilitating a decreased waste of sheet material. Additionally, as compared to typical hand-forming of containers from blanks, the example embodiments advantageously facilitate a faster process in which a single operator may form containers at a plurality of box-forming stations, without a need for the operator to physically relocate himself or herself from one station to the next and/or carry blanks from one station to the next. Moreover, the example embodiments do not require electrical power, a flat floor, or other infrastructure support, and thus facilitate providing the above-described advantages in a field location that may be remote from such infrastructure.

Example embodiments of methods and a machine for forming a container from a blank are described above in detail. The methods and machine are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the machine may also be used in combination with other blanks and containers, and is not limited to practice with only the blank and container described herein.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

What is claimed is:
 1. A machine for forming a container from a blank of sheet material, said machine comprising: a base; a frame coupled for rotation about said base; and a plurality of box-forming stations coupled to said frame, each box-forming station comprising: a mandrel coupled to said frame, said mandrel comprising: a bottom face having two pairs of opposing edges; a pair of opposing side faces and a pair of opposing end faces, each said side face and end face extends generally from a corresponding edge of said bottom face and is perpendicular to said bottom face; a first pair of opposing presses each configured to be moved into close proximity to a respective end face of said pair of opposing end faces; a second pair of opposing presses each configured to be moved into close proximity to a respective side face of said pair of opposing side faces; and at least one manually operable mechanism configured to control a position of a first press from among the first pair of opposing presses and the second pair of opposing presses.
 2. A machine in accordance with claim 1, wherein said first pair of opposing presses comprises a first end wall press and a second end wall press each movably coupled to said frame.
 3. A machine in accordance with claim 2, wherein said first end wall press and said second end wall press each are movable between a receiving position, wherein a face of said respective end wall press is positioned away from a corresponding end face of said pair of opposing end faces of said mandrel, and a pressure position, wherein said face of said respective end wall press is positioned in close proximity to said respective end face of said mandrel.
 4. A machine in accordance with claim 3, wherein said at least one manually operable mechanism comprises a lever, said second end wall press is operably coupled to said lever such that: said second end wall press is in the receiving position when said lever is in a first position; and said second end wall press is in the pressure position when said lever is in a second position.
 5. A machine in accordance with claim 3, wherein said at least one manually operable mechanism comprises an interface plate, said first end wall press is operably coupled to said lever such that: said first end wall press is movable to the receiving position when a first cross bar of said first end wall press is received in a catch slot defined in said interface plate; and said first end wall press is movable to the pressure position when the first cross bar is received in a release slot defined in said interface plate.
 6. A machine in accordance with claim 1, wherein said frame is configured to rotate about a generally vertical axis, said base comprises at least one leg, said at least one leg is extended to a distance from the axis that is greater than a distance of a fulcrum of said lever from the axis.
 7. A machine in accordance with claim 1, wherein said second pair of opposing presses comprises a first side wall press and a second side wall press each movably coupled to said frame, said first side wall press and said second side wall press each are movable between a receiving position, wherein a side face of said respective side wall press is positioned away from a corresponding side face of said pair of opposing side faces of said mandrel, and a pressure position, wherein said side face of said respective end wall press is positioned in close proximity to said respective side face of said mandrel.
 8. A machine in accordance with claim 7, wherein each said box-forming station further comprises a locking mechanism configured to releasably maintain each of said first side wall press and said second side wall press in the pressure position.
 9. A machine in accordance with claim 1, wherein said bottom face has a shape that substantially corresponds to a shape of a bottom panel of the blank, said pair of opposing side faces each have a shape that substantially corresponds to a shape of each of a pair of side panels of the blank, and said pair of opposing end faces each have a shape that substantially corresponds to a shape of each of a pair of end panels of the blank.
 10. A machine in accordance with claim 9, wherein each of said first end wall press and said second end wall press is configured to rotate a respective end panel of the blank about a respective end edge of the blank into a position perpendicular to the bottom panel to at least partially form a respective end wall of the container when said respective end wall press is moved from the receiving position to the pressure position.
 11. A machine in accordance with claim 9, wherein each of said first side wall press and said second side wall press is configured to rotate a respective side panel of the blank about a respective side edge of the blank into a position perpendicular to the bottom panel to at least partially form a respective side wall of the container when said respective side wall press is moved from the receiving position to the pressure position.
 12. A machine in accordance with claim 9, wherein said mandrel bottom face further comprises two pairs of opposing corner edges, said mandrel further comprises a plurality of corner faces, each said corner face extends generally from a corresponding corner edge of said bottom face and is perpendicular to said bottom face, and wherein each end panel of the pair of end panels includes a pair of reinforcing panel assemblies extending from opposing edges of the end panel, each reinforcing panel assembly includes at least one corner panel, each said mandrel corner face has a shape that substantially corresponds to a shape of the at least one corner panel.
 13. A machine in accordance with claim 12, wherein each of said first side wall press and said second side wall press includes at least one mitered face configured to rotate the at least one corner panel extending from at least one of the end panels about a respective edge of the respective end panel to at least partially form a respective corner wall of the container when said respective side wall press is moved from the receiving position to the pressure position.
 14. A method for forming a container from a blank of sheet material using a machine that includes a mandrel, the blank including a bottom panel, a first and second side panel each extending from a respective side edge of the bottom panel, a first and second end panel each extending from a respective end edge of the bottom panel, a first and fourth reinforcing panel assembly each extending from a respective side edge of the first end panel, and a second and third reinforcing panel assembly each extending from a respective side edge of the second end panel, said method comprising: positioning each of a first end wall press, a second end wall press, a first side wall press, and a second side wall press in a receiving position, wherein each of the first end wall press, the second end wall press, the first side wall press, and the second side wall press are movable between the receiving position and a pressure position; aligning the bottom panel with a bottom face of the mandrel; moving the first end wall press from the receiving position to the pressure position such that the first end panel is pressed between the first end wall press and a first end face of the mandrel to at least partially form a first end wall of the container; moving the second end wall press from the receiving position to the pressure position such that the second end panel is pressed between the second end wall press and a second end face of the mandrel to at least partially form a second end wall of the container; moving the first side wall press from the receiving position to the pressure position such that the first side panel, at least a portion of the first reinforcing panel assembly, and at least a portion of the second reinforcing panel assembly are pressed between the first side wall press and a first side face of the mandrel to at least partially form a first side wall of the container; and moving the second side wall press from the receiving position to the pressure position such that the second side panel, at least a portion of the third reinforcing panel assembly, and at least a portion of the fourth reinforcing panel assembly are pressed between the second side wall press and a second side face of the mandrel to at least partially form a second side wall of the container.
 15. A method in accordance with claim 14, wherein said moving the first end wall press from the receiving position to the pressure position comprises operating a first manually operable mechanism of the machine.
 16. A method in accordance with claim 15, wherein said operating the first manually operable mechanism comprises receiving a first cross bar of the first end wall press in a release slot defined in an interface plate of the first manually operable mechanism.
 17. A method in accordance with claim 14, further comprising releasably locking the first side wall press and the second side wall press in the pressure position.
 18. A method in accordance with claim 14, wherein the first and second reinforcing panel assemblies each include at least one corner panel, and wherein moving the first side wall press from the receiving position to the pressure position comprises: pressing the first side panel, at least a portion of the first reinforcing panel assembly, and at least a portion of the second reinforcing panel assembly between a side face of the first side wall press and a first side face of the mandrel to at least partially form the first side wall of the container; pressing the at least one corner panel of the first reinforcing panel assembly between a first mitered face of the first side wall press and a second corner face of the mandrel to at least partially form a first corner wall of the container; and pressing the at least one corner panel of the second reinforcing panel assembly between a second mitered face of the first side wall press and a third corner face of the mandrel to at least partially form a second corner wall of the container.
 19. A method in accordance with claim 18, wherein the third and fourth reinforcing panel assemblies each include at least one corner panel, and wherein moving the second side wall press from the receiving position to the pressure position comprises: pressing the second side panel, at least a portion of the third reinforcing panel assembly, and at least a portion of the fourth reinforcing panel assembly between a side face of the second side wall press and a second side face of the mandrel to at least partially form the second side wall of the container; pressing the at least one corner panel of the third reinforcing panel assembly between a second mitered face of the second side wall press and a fourth corner face of the mandrel to at least partially form a third corner wall of the container; and pressing the at least one corner panel of the fourth reinforcing panel assembly between a first mitered face of the second side wall press and a first corner face of the mandrel at least partially form a fourth corner wall of the container.
 20. A method in accordance with claim 14, wherein each of the first, second, third, and fourth reinforcing panel assemblies includes, extending in series extending from the respective side edge of the respective end panel, an outer reinforcing panel assembly and an inner reinforcing panel assembly, and wherein the outer reinforcing panel assembly includes a corner panel and a first reinforcing side panel, and the inner reinforcing panel assembly includes a second reinforcing side panel and an inner reinforcing corner panel, said method further comprises rotating each inner reinforcing panel assembly towards an interior surface of the corresponding outer reinforcing panel assembly such that the corner panel and inner reinforcing corner panel are substantially aligned in an at least partially overlying relationship, and the first and second reinforcing side panels are substantially aligned in an at least partially overlying relationship, and said moving the first side wall press from the receiving position to the pressure position comprises: pressing the first side panel, the aligned first and second reinforcing side panels of the first reinforcing panel assembly, and the aligned first and second reinforcing side panels of the second reinforcing panel assembly between a side face of the first side wall press and a first side face of the mandrel to form the first side wall of the container; pressing the aligned corner panel and inner reinforcing corner panel of the first reinforcing panel assembly between a first mitered face of the first side wall press and a second corner face of the mandrel to form a first corner wall of the container; and pressing the aligned corner panel and inner reinforcing corner panel of the second reinforcing panel assembly between a second mitered face of the first side wall press and a third corner face of the mandrel to form a second corner wall of the container.
 21. A method in accordance with claim 20, wherein said moving the second side wall press from the receiving position to the pressure position comprises: pressing the second side panel, the aligned first and second reinforcing side panels of the third reinforcing panel assembly, and the aligned first and second reinforcing side panels of the fourth reinforcing panel assembly between a side face of the second side wall press and a second side face of the mandrel to form the second side wall of the container; pressing the aligned corner panel and inner reinforcing corner panel of the third reinforcing panel assembly between a second mitered face of the second side wall press and a fourth corner face of the mandrel to form a third corner wall of the container; and pressing the aligned corner panel and inner reinforcing corner panel of the fourth reinforcing panel assembly between a first mitered face of the second side wall press and a first corner face of the mandrel to form a fourth corner wall of the container.
 22. A method in accordance with claim 20, wherein each of the first, second, third, and fourth inner reinforcing panel assemblies further includes an inner reinforcing end panel, said rotating each inner reinforcing panel assembly towards an interior surface of the corresponding outer reinforcing panel assembly further includes rotating each inner reinforcing panel assembly such the inner end panel and at least a portion of the respective end panel are substantially aligned in an at least partially overlying relationship, wherein: said moving the first side wall press from the receiving position to the pressure position comprises pressing the inner end panel of the first reinforcing panel assembly, the inner end panel of the fourth reinforcing panel assembly, and the first end panel between the first end wall press and the mandrel first end face to form the first end wall of the container; and said moving the second side wall press from the receiving position to the pressure position comprises pressing the inner end panel of the second reinforcing panel assembly, the inner end panel of the third reinforcing panel assembly, and the second end panel between the second end wall press and the mandrel second end face to form the second end wall of the container.
 23. A method in accordance with claim 14, wherein said moving the second end wall press from the receiving position to the pressure position comprises operating a second manually operable mechanism of the machine.
 24. A method in accordance with claim 23, wherein said operating the second manually operable mechanism comprises moving a lever of the second manually operable mechanism from a first position to a second position.
 25. A method for forming a plurality of containers from blanks of sheet material by an operator using a machine that includes a plurality of box-forming stations coupled to a frame, said method comprising: wrapping a first blank about a mandrel of a first box-forming station that is proximate to the operator; rotating the frame about a base of the machine such that a second box-forming station arrives proximate to the operator; wrapping a second blank about a mandrel of the second box-forming station; rotating the frame about the base of the machine such that the first box-forming station arrives proximate to the operator; and removing the wrapped first blank from the mandrel of the first box-forming station after an adhesive on the first blank substantially sets to form a first container.
 26. A method in accordance with claim 25, further comprising locking a locking mechanism configured to maintain the first blank in the wrapped configuration about the mandrel while the adhesive on the first blank sets.
 27. A method in accordance with claim 25, wherein said wrapping a first blank about a mandrel of a first box-forming station comprises setting each of a first end wall press, a second end wall press, a first side wall press, and a second side wall press to a pressure position.
 28. A method in accordance with claim 27, wherein said setting the first end wall press to the pressure position comprises receiving a first cross bar of the first end wall press in a release slot defined in an interface plate, and said setting the second end wall press to the pressure position comprises moving a lever from a first position to a second position.
 29. A method in accordance with claim 25, wherein said rotating the frame about a base of the machine such that a second box-forming station arrives proximate to the operator comprises pushing the first box-forming station to a side, allowing the frame to rotate until the second box-forming station arrives proximate to the operator, and halting the rotation by placing a hand on the second box-forming station.
 30. A method in accordance with claim 25, further comprising wrapping a third blank about the mandrel of the first box-forming station after the first blank is removed to form the first container. 